2-shot molded vapor seal

Abstract

An electrical box including a flange produced utilizing a 2-shot molding process and provided as a unitary structure. The flange has a first surface and a second surface, wherein the first surface and the second surface are substantially co-planar, spaced apart, and generally parallel to a plane defined by an open end of the electrical box when the electrical box is installed into a corresponding wall structure. The flange is self-supporting and flexible to accommodate dimensional and alignment irregularities in a mounting surface. Each of a plurality of knock outs formed in the electrical box has a slit formed therein that retains passed-through cables, as well as closes and returns to an original undisturbed position when the cables are removed to maintain substantially air tight conditions.

What is claimed is: 
     
       1. An electrical box assembly comprising:
 a box structure including a closed end, an oppositely arranged open end, and an interior surrounded by at least one sidewall connecting the open end to the closed end; 
 a flange extending outwardly from an outer surface of the at least one sidewall at a position intermediate the open end and the closed end of the box structure, the flange formed from a resiliently flexible material, and 
 at least one knock out disposed within an opening formed in one of the at least one sidewall or the closed end of the box structure, the at least one knock out formed from the same material as the flange, wherein the at least one knock out and the flange are formed as a unitary structure. 
 
     
     
       2. The electrical box assembly according to  claim 1 , wherein the unitary structure is formed in an overmolding process performed on the box structure. 
     
     
       3. The electrical box assembly according to  claim 1 , wherein the unitary structure further comprises at least one connecting portion extending between and connecting the flange to the at least one knock out. 
     
     
       4. The electrical box assembly according to  claim 3 , wherein the connecting portion is disposed within an indented portion of the outer surface of the at least one sidewall. 
     
     
       5. The electrical box assembly according to  claim 1 , wherein the flange includes a first surface facing towards the open end of the box structure and an opposing second surface facing towards the closed end of the box structure. 
     
     
       6. The electrical box assembly according to  claim 5 , wherein the first surface and the second surface of the flange are arranged transversely relative to an axial direction of the box structure extending in a direction from the open end to the closed end of the box structure. 
     
     
       7. The electrical box assembly according to  claim 6 , wherein the first surface and the second surface are inclined relative to the axial direction of the box structure. 
     
     
       8. The electrical box assembly according to  claim 7 , wherein the first surface and the second surface are inclined towards the open end of the box structure as the flange extends away from the outer surface of the at least one sidewall. 
     
     
       9. The electrical box assembly according to  claim 1 , wherein the flange has a perimeter shape corresponding to a perimeter shape of the box structure. 
     
     
       10. The electrical box assembly according to  claim 1 , wherein the flange is spaced from the open end of the box structure to accommodate a thickness of an associated wall structure between the open end and the flange. 
     
     
       11. The electrical box assembly according to  claim 10 , wherein the flange abuts a collar surrounding the open end of the box structure. 
     
     
       12. A method of manufacturing an electrical box assembly comprising the steps of:
 molding a box structure in a first shot of a molding process, the box structure including a closed end, an oppositely arranged open end, and an interior surrounded by at least one sidewall connecting the open end to the closed end; 
 molding a flange onto the box structure in a second shot of the molding process, the flange extending outwardly from an outer surface of the at least one sidewall at a position intermediate the open end and the closed end of the box structure. 
 
     
     
       13. The method according to  claim 12 , wherein the first shot of the molding process includes a first material and the second shot of the molding process includes a second material different from the first material. 
     
     
       14. The method according to  claim 13 , wherein the first material is rigid at room temperature and the second material is resiliently flexible at room temperature. 
     
     
       15. The method according to  claim 13 , wherein the second material is introduced into a mold at a position adjacent the closed end of the box structure. 
     
     
       16. The method according to  claim 12 , further comprising the step of molding of at least one knock out into an opening of the electrical box during the second shot of the molding process. 
     
     
       17. The method according to  claim 16 , wherein the at least one knock out and the flange form a portion of a unitary structure. 
     
     
       18. The method according to  claim 16 , wherein a connecting portion connects the at least one knock out to the flange. 
     
     
       19. An electrical box assembly comprising:
 a box structure including a closed end, an oppositely arranged open end, and an interior surrounded by at least one sidewall connecting the open end to the closed end; 
 a flange extending outwardly from an outer surface of the at least one sidewall at a position intermediate the open end and the closed end of the box structure, the flange formed from a resiliently flexible material, wherein the flange includes a first surface facing towards the open end of the box structure and an opposing second surface facing towards the closed end of the box structure, wherein the first surface and the second surface of the flange are arranged transversely relative to an axial direction of the box structure extending in a direction from the open end to the closed end of the box structure, and wherein the first surface and the second surface are inclined relative to the axial direction of the box structure. 
 
     
     
       20. The electrical box assembly according to  claim 19 , wherein the first surface and the second surface are inclined towards the open end of the box structure as the flange extends away from the outer surface of the at least one sidewall.